Apparatus for producing corrugated structures



Aug. 20, 1.946. G, wElss APPARATUS FOR PRODUCING CORRUGATED STRUCTURES Filed June 26, v1943 5 Sheets-Shea?f 1 y Fig. 2

INVENTOR. Ger-)fart Zrz'ss BY ATTR/VEYS Aug. 20, 1946. 'ca wElss APPARATUS FOR PRODUCING CORRUGATED STRUCTURES Filed June 26, 1945 s sheetsheet 2 V EN TOR. 6er/uff 7/6/ s A Aug; 2o, 194e. G. WE1-ss 2,406,051

APPARATUS FOR PRODUCING CORRUGATED STRUCTURES Filed June 26, 1945- s shets-sheet s IN VEN TOR. Gerhart Zt/ez'ss 'BY /m I ATTORNEYS Patented Aug. 20, 1946 UNITED STATES 'rrr OFFICE APPARATUS FOR PRODUCING CORRGATED STRUCTURES Gardens, N. Y.

Application June 26, 1943, Serial No. 492,409

1. Claim.

provide a novel apparatus for continuously forming resin impregnated corrugated structures of tubular shape.

It is a further object of the present invention to provide a continuous apparatus for forming Y .resin impregnated corrugated structures which contain metal inserts or core elements.

It is a further object of the present invention to provide a continuous process for shaping resin impregnated fibrous sheets to corrugated form and `enclosing in the continuation of the same operation, said corrugated structure within the resin impregnated liner elements.

Further objects will be apparent from a consideration of the drawings and a specific description thereof which here follows.

Figure 1 is a side schematic View ofthe appa-A ratus for forming a corrugated structure.

Figure 2 is a cross section taken along the line 2-2 of Figure 1 showing the Ycorrugated forming elements. n

Figure 3 is a cross section of the corrugated element formed according to my invention.

Figure 4 is a perspective end view of the corrugated structure forming apparatus of my invention.

Figure 5 is a perspective view of another form of my invention showing the apparatus and means by which tubular corrugated structures can be continuously formed.

Figure 6 is a cross section of the apparatus of Fig. 5 along the line -G of Figure 6.

Figure 7 is a cross section taken along the line l-l of Figure 5.

Figure 8 is a perspective of the tubular corrugated structure formed by the apparatus shown in Figure 5. l

Figure 9 is a detailed perspective showing the application of the sealing strip to the joint of the tubular corrugated structure.

Figure 10 is a partial cross section showing the sealing of the tubular corrugated structure by the tape as shown in Figure 9.

Figure l1 is another modified forming of my apparatus in which I show an apparatus for continuously producing a corrugated structure.

Figure 12 is a cross section of a modified form of my invention.

Referring now more specifically to Figure 1, Figure 2 and Figure 4, I show a roll I of resin impregnated fibrous material such as paper, which has been impregnated with aurea or phenol formaldehyde condensation product or a thermo plastic resin such as a vinyl compound, as for example vinyl acetate, vinyl chloride or copolymers thereof lor polyvinyl acetal, butyral etc. The resin impregnated paper I passes rst under lshaping elements 2 supported by rods 3 from a support 4. The shaping elements 2 comprise long rods which extend longitudinally along the `apparatus and which rods may terminate at the end 5 of the upper element 6 of the pressing apparatus which presses the upper liner element I on to the corrugated element.

The core members 2 may have a shape dictated t by the shape of the corrugations to be formed and here are in the form of curved members so that the conventional curved or sine wave corrugation is formed.

The support 5 and the supporting elements 3 firmly hold the shaping rods 2 in position so that the corrugations are formed in proper space relation with one another.

From an adhesive tank 9 adhesive is supplied through a doctor element I0 on to the upper portions of the corrugated sheet I so that whenthe resin impregnated corrugated liner element I is fed down onto the corrugatedsheeting I and pressed thereon by the upper pressing element 6, adhesion is effected between the liner element 'I and the corrugated sheeting I. The corrugated sheeting passes over the table I2 where it may be heated to first effect the softening of the thermo plastic resin with which the corrugated and liner elements have been impregnated.

From an adhesive tank I3, adhesive is fed through a tube I4 and `a doctor applicator I5 through the bottom of the corrugated sheeting I whereupon a bottom liner element I6 is pressed on to the bottom of the corrugated sheeting I by a pressure element I'I. By means of this apparatus I can lcontinuously f-orm a corrugated sheeting in wh'ich'the corrugations are properly molded into the resin impregnated sheeting I and this precise corrugated structure ismaintained ment that can be spread by pressure downwardly applied thereto. v Y In Figure I show an apparatus an'd a'metho by means of which I can continuously form tubular corrugated resin impregnated structures. From a roll a sheet of resin impregnatedpaper 2i is fed between an external-corrugated shaping Y element 22 and an internal corrugated shaping element 23 made up of a series of "rods havingfa shape that conforms to the inside shape o the shaping member 22. The resin impregnated paper n 2l passes between the shaping elements 22 and 23 vand may Ebe -preiirninarily softened by heating if -the resin-Which impregnatesthelpaperis thermoplastic or heat Vsoftenable. Upon beingsosoitened, the paper as fit passesbetWeen-the shaping mem- "ber-s 22 and 123 AvformsY to a corrugated shape.

A resin impregnated liner sheet 25Vis fed `from va roll 528 and `adhesive is applied to the outer surface thereof from an adhesive tank?! through an adhesive applicator ring 28; "The adhesive coatedliner material Jv25 @is then lled overa-secz tional s'hell (see Figure@ Wherebyit ispressed into adhesive vcontact :With the resin impregnated paper 2'! -Wliich has been :shaped fto l corrugated form. The sectional shells "39 are supported by arms'EZ whicharesupported'centrallybya i=od`33.

I 1A steamilineliirunslthrough the rod 33 y"to supiply Eheat to" soften the vresin impregnated corrugated liner 'elements "for theirI shaping `and 'adherence' and infthe case ofthe 'use of a'thermo settingresinftoapplyheat theretoto efectialcur- Vadhesively secured over the `corrugatedsheeting 21. Thus; by continuous operation "I shape a resin impregnated sheet to corrugated formv'and while lin such '"corrugated'fform' 1I attac'h iin fadhesive relation A.thereto an inner'liner element 25 and anouter 'liner `element I4 I V"IThe napplication of -heat is so controlled thatin the case o'f jatherino plastic resin being used, the heat lis-applied to soften the resin and after shaping ATis leiiected'the structure iis-coolerd either by the nonuse of heat or by theuse of cooling means to set the thermo Yplastic resin impregnated sheet Ain 'the structure formed.

VFigure Gis a cross vsectional View, taken along theline-S` of Figure 5. p

Figure 7,is across section taken-alongthe vline Figures 6 and v7 Vare cross sectional views that Willa'ssist in the understanding of theperation orftheapparatus/shown'in Figure. 1` f l In-Figure 8` Ishow the resin impregnated corrugated tubular structure which is a 'product of the apparatus and method shown in `Figures '5, 6

From a roll lia lsheetoi resin iml and 7, and which comprises the inner liner 25, the outer liner tl and the corrugated element 2 l The inner liner 25 is overlapped at i4 and the outer liner ii is overlaped at 45, this overlapping of the liner elements as well as of the corrugated Aelement 2i being effected to secure a firm adhesive end joint.

In Figure 9 I show a modification of my in- Yvention in which the end joining of the liner elefment is-ei-ected by the application of an adhesive tape E to the joint Where the outer liner element meets and a pressure member 5| firmly applies theadhesive tape 5@ -to the joint.

In Figure l0 I show a cross section of a corrugated structure so formed in which the adhesive tape dii is applied over the outer liner element 4I.

AIn Figure 11 I show the apparatus for continuously forming a corrugated structure in which a strip of resinimpregnated brous Inaterial 86 is fed from a roll 3l through a first set-of shaping rolls S2-an`d 33 which apply ageneral vcorrugated shape to the plastic strip 89 and a second set of shaping rolls 8'4 and 85 which -impart a block shaping to the strip material. The block shaped corrugated strip material is carried along 'between rods 'and 89 Which are fed by means of tracks Si) and 9| into the openings in the corrugated strip 8B -so that a rod insert fallsinto each opening as shown. The rods are disposed in opposed relation to one another for the purposes explained hereinafter.

When the rod is to remain in place after manufacture as in the manufacture of armor plating, then the rod is coated with an adhesive. When the rod simply-actsas acore to facilitate in proper shaping of the corrugated element, then the `rod is coated with alubricating compositionrwhich may be either a lubricant'bypits fowncharacteristic or a substance which upon Aapplication of heat adjacent thereto becomes soft and the rod can thus beV disengaged therefrom..` ,y

The corrugated strip with the rods 88 and 89 new positioned lin adjacent corrugations theres of pass ,throughgrollsQZ and 93 which operate at a higher speed than the roller members next encountered in the apparatus. and accordingly press Ythe corrugations so as to'close the corruga- `tionsabout the core elementsandrform triangular-enclosures aboutsaid core members l88 and 8.9. Y From Van adhesive tank such as ltl, adhesive 'is applied by means of doctor elements 9S and 91 to the externalrportions of the Vcorrugations 8i). fI'he adhesive coated. corrugated resin Aimpregnated strip 8% With'the cores contained therein then passes between two chromium plated continuous belts IQll and lill which are rotated over rolls m2 andrllJS by a suitable driving mechanism. The chromium plated belts 1D0 and 10i come in smooth and slipping contact with the liner elements i634 and which are applied upon the adhesive coated corrugated strip element Sil. A pair of continuously rotating endless plate blcck chains IBS and |01 rotating Y about wheels H18, |09, H0, HI, yact to transmit pressure vfrom the hydraulic press H3 through theV ball bearing surface IM thereon and from stationary platen-H5 and the ball bearing surface lll thereon. Y

Pressuretrarismitted from the hydraulic rpress H3 is applied 'through ball bearingsjl I4 seated inthat surface on to the heavy plates V'H36 and similar pressure is applied trom the table 'H6 below to the ball bearings H1 to the 'track lill, the tracks H36 and` il' applying fpressure't'hrough the chromium belts lill to the corrugated strip 80 positioned between the liner elements |04 and m5. Thus I lirmly apply pressure to the corrugated structure to `cause the thermo plastic to flow and set, or in the case of a thermosetting compound, to cause the thermosetting compound, which is impregnated into the fibrous material, to be cured and to firmly bond all parts ofV the corrugated structure together.- By the heat application set out herein, a hard strong resin impregnated corrugated structure is obtained. n

I may also employ as the limpregnated agent Vinsol, sold by the Hercules Powder Co. and which is an extract of yellow pine trees, certain silicates, such as sodium and potassium silicate, preferably treated with an acid so that the silicate is set in place'in the fibrous material, vinylidine chloride and chlorinated parans. These resins may also be applied tothe fibrous material by dipping, spraying, brushing or any other suitable applicator meansv and heat and subsequently cold is applied to take advantage of the thermo plastic nature of the materials employed.

It is also within the scope of my invention to form the corrugated middle elements, such as element l shown in Figure 3, or the element` 8u shown in Figure' 12, by extruding a plastic mass comprising sawdust, or wood our in a mix ccmprising an adhesive, the mix being extruded through a die having a cross section depending on the type of corrugatiou involved. In other words the corrugated element is extruded in its corrugated form through the die and the plastic mass that forms the corrugated element sets as it emerges from the die.

Hot air or other suitable heating means may assist in the setting and drying of the extruded corrugated material.

I may employ as the composition to be eX- truded in the form of a corrugated structure a mass comprising excelsior or Wood wool and a binder whichmay comprise lignin or alternatively a suitable thermosetting or a thermoplastic resin such as for example phenol formaldehyde condensation product or any of the well known vinyl compounds or other suitable adhesive' resincus or plastic compositions well known in this art. The excelsior is boiled in dilute sulphuric acid, then drained, and neutralized,

whereupon it may be molded, pressed or extruded with the addition of aniline or furfural if a resinous combination is desired. Alternatively to using excelsior as the base material, I may employ cotton ock.

The complete corrugated structure comprising upper and lower liners and the centrally attached corrugated element is extruded. The apparatus used is an extrusion die with upper, and lower slots and a central sine curve slot that meets the upper and lower slots, the central slot being formed for example by a series of curved blocks set in the die head.

When the composition extruded is thermoplastic, it is heated prior to extrusion and cooled after extrusion.

Suitable heat may be applied by hot air or steam or hot water pipes and cooling means by suitable cooling and refrigerating devices in Zones which are determined by the particular nature of the thermosetting or thermoplastic resin to be employed.

If the rods 88 and 89 are to be withdrawn having simply been used as core elements, then I may apply heat directly through the rods 88 and 89 as `by-electric current orlby heat by conduction to cause the coatings thereon to'soften and lose their adhesive qualitie'sL- The rods may thereuponv be withdrawn from the corrugations.

In making an armorplating or other building structure in Which the rods or tubular inserts 83 and 89 are to be left in place, no such means of withdrawal need be provided 'In Figure 12 I show the corrugated structure formed according to the apparatus shown and described above in which the corrugated strip element 8E! is rmly bonded between the upper liner element lili vand the lower liner element |85.

It will be understood that the apparatus shown and described hereinabovel can be varied by those skilled in the art without departing from the spiritcf myinvention. For example, in Figure ll -the crimping orcorrugating rolls 32, 33, 84 and 85, maybe modified in shape to produce a curved corrugati'on instead'of the rectangular corrugation shown herein. In that case curved cores or inserts 88 and 89 would be employed.I The mechanisms involved would still be substantially the same.

Various types of resins may be used for impregnating the brous material to form the corrugated structures described herein.' For example reference is made to my copending application Serial No. 484,503 which described certain therino-setting resins vwhich are applied to the fibrous material and which are set by heat and pressure.

I have found that I may obtain a very strong resin impregnated corrugated structure by using diethylene chloride-polystyrene resin, the reaction of which is accelerated by the use of a peroxide as a catalyst. Whereas it is necessary in the case of the phenol formaldehyde condensation resins to employ pressure, in the curing thereof, it is unnecessary to usepressure in curing the diethylene chloride-polystyrene resin. The resin is rst heated to a range of l0-80 C. and secondly to a range of 10G-120 C. The fibrous materia] may be impregnated with the resin either by dipping, spraying, brushing or the like.

It is much more dimcult from an operating standpointto employ core elements which must be withdrawn and pressure apparatus in forming corrugated structures than to use simple joining means, It is the object of the present invention to form a corrugated structure impregnated with a hard resin without the necessity for using pressure apparatus and core members. It is a further object of the present invention to make a resin impregnated corrugated structure having relatively high impact strength and substantial tensile strength.

The resin such as the diethylene chloride-polystyrene condensation product which can be cured by heat alone and without the use of pressure is therefore extremely valuable in making a resin impregnated corrugated structure of high impact and high tensile strength without the necessity for using pressure apparatus.

It will be understood that the apparatus and method herein described can be used not only for the manufacture of corrugated structures from resin impregnated sheeting, but may also be used for the manufacture of corrugated sheeting from plain coated or resin impregnated 1ibrous material such as paper or cardboard, since the shaping and forming apparatuses are believed novel.

In addition to employing paper or cardboard, I may form corrugated structures from cloth, as for example cotton duck, or from cloth woven from glass fibre, such cloths being impregnated with a thermoplastic or thermoadhesive compound, such as phenol formaldehyde or vinyl acetate so that such cloth has when set suicient rigidity and structural strength to maintain the corrugated structure.

By employing different resins of the type set forth above, I may vary the properties of the nal corrugated structure produced so that I may produce a reproof, Water resistant, resin impregnated corrugated structure having either hardness or resilient strength or I may com-bine various compositions to obtain for example a corrugated structure having an external coating giving high impact strength and an internal impregnating resin which gives toughness and resilience to the corrugated structure.

The application of adhesives in forming the corrugated structuresshown hereinabove will be covered of course by the nature of the material employed. When plain sheet material is employed, then adhesives are necessary to induce adhesion between the liner elements and the corrugated element. When resin impregnated sheet material is employed, the use of added adhesives will depend on whether adhesion can be induced between adjacent sheets by the use of heat and pressure alone as in the case of thermoplastics.

In the case of the use of certain thermcsetting impregnated resins adhesion will be induced during the curing of the impregnated sheets when pressed into contact With one another. In other instances added adhesives will be necessary depending upon the strength of the joint required.

Various modicatio-ns of my invention will suggest themselves to those skilled in the art. I accordingly desire that in construing the breadth of the appended claim that they shall not be limited to the specific details shown and described in connection with the above explanation.

I claim:

An apparatus 4for continuously producing co-rrugated material which comprises means for preshaping brous sheet material, a second means for shaping said sheet material into rectangular corrugated form, means for introducing core mem-bers into the corrugations formed in said corrugated material, means for advancing said corrugated material containing said core members, means for pressing liner elements in contact with said corrugated material containing said core members, said means for advancing said corrugated material moving at a greater rate of speed than said means for pressing liner elements onto said corrugated material.

GERHART WEISS. 

